Ericsson Inc.Private Radio SystemsMountain View RoadLynchburg, Virginia 245021-800-528-7711 (Outside USA, 804-528-7711) Printed in U.S.A.

ericssonz

LBI-38901F

Installation Manual

Orion™ Mobile Radio

2

TABLE OF CONTENTS

INTRODUCTION................................................................................3UNPACKING AND CHECKING EQUIPMENT................................3PLANNING THE INSTALLATION ...................................................6EQUIPMENT REQUIRED..................................................................8INSTALLATION IN VEHICLES POWERED BY LIQUEFIED(LP) GAS..............................................................................................9INSTALLATION .................................................................................9

RUNNING CABLES...................................................................9Power Cable........................................................................12Accessory Cable .................................................................13Ignition Sense .....................................................................20Control Cable (Remote Mount Only) .................................21

CONTROL UNIT MOUNTING (REMOTE APPLICATIONSONLY)................................................................................21

SPEAKER D2LS1F...................................................................26MICROPHONE HANGER AND/OR HOOKSWITCHMOUNTING .............................................................................26RADIO MOUNTING AND FINAL HOOK-UP.......................27

Front Mount........................................................................27Remote Mount Installation .................................................29Cassette Mounting (EURO Only) .......................................30Cassette Assembly Mounting..............................................31

DUAL CONTROL UNITS.................................................................34PREINSTALLATION PROGRAMMING PROCEDURE

-- FRONT MOUNT............................................................34PREINSTALLATION PROGRAMMING PROCEDURE

-- REMOTE MOUNT ........................................................36INSTALLATION PROGRAMMING FOR FRONT MOUNT

DUAL CONTROL UNITS.................................................38INSTALLATION INSTRUCTIONS FOR REMOTE MOUNT

DUAL CONTROL UNITS.................................................39DUAL RADIO UNITS.........................................................................43

This manual is published by Ericsson Inc., without any warranty. Improvements andchanges to this manual necessitated by typographical errors, inaccuracies of currentinformation, or improvements to programs and/or equipment, may be made by EricssonInc., at any time and without notice. Such changes will be incorporated into new editionsof this manual. No part of this manual may be reproduced or transmitted in any form or byany means, electronic or mechanical, including photocopying and recording, for anypurpose, without the express written permission of Ericsson Inc.

Copyright© October 1993 Ericsson GE Mobile Communications Inc.

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Figure 38 Dual Radio Control Cable (19B802554P10)

(19B802554, Sh.8, Rev. 19)

46

Figure 36 - Orion Dual Radio Front Mount InstallationConfiguration

Figure 37 - Orion Dual Radio Remote Mount InstallationConfiguration

3

INTRODUCTIONThis manual contains installation instructions for the Orion Mobile RadioUnit and associated accessories. These instructions cover the mountingand cabling of the radio; interconnection and wiring diagrams areprovided for reference. Before installation the radio should beprogrammed using an IBM compatible personal computer and thefollowing items:

Serial/Flash Programming Interface Module TQ3370

Programming Cable TQ3377

EDACS Programming Software TQ3374

or

Conventional Programming Software TQ3367

IMPORTANT NOTICE

ORION UHF MOBILES

The PC programmer automatically defaults the receiver oscillator shift toposition No. 2. When field programming the receive frequencies forORION UHF mobiles, the oscillator shift must be programmed toposition No. 1 or No. 3. Enter the CONVENTIONAL and/or TRUNKEDFREQUENCY SET screen of the PC programmer and set the values inthe “OS” column to “1” or “3”.

UNPACKING AND CHECKING EQUIPMENTCarefully unpack the radio and identify each item in the shippingcontainer as listed below. If damage has occurred to the equipmentduring shipment, file a claim with the carrier immediately. The availableoptions for the Orion Mobile Radio are covered in Table 1.

• Orion Mobile Radio Unit

• Microphone D2MC3W or D2MC3Z

• Speaker D2LS1F or D2LS1H

• Power Cable D2CE1V or D2CF9A

• Control Cable D2CE1Y

4

• Front Mount Bracket Kit D2MA3N

or

• Remote Mount Kit D2MA3R

with

• Control Unit Mount Kit D2MA3J

• Operator's Manual LBI-38888

• Installation Manual LBI-38901

Figure 1 - Orion Mobile Radio Components And Mounting Hardware

Figure 2 - Rear View Of Radios

USA EURO

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2. After installing Master Radio Unit mounting hardware, connect theDual Radio Cable Connector (P3) to the Master Radio Unit. Tightenthe two jackscrews on P3.

3. Next route the Remote Control Cable (19B802554P3 or P4) betweenControl Head and Master Radio locations. After installing ControlHead, connect Remote Control Cable Connector (P2) to Control Head.

4. Connect "IGN A+" lead, if option is desired. Be sure internal SwitchSW601 on Master Radio is set properly. Refer to Page 20 of thismanual for details.

5. Connect Accessory Cable (19B802554P6 or P7) Connector (P1) toControl Head.

6. Connect Microphone and Accessories. Refer to Accessory InstallationManual for proper connection of Accessories.

7. Now connect Remote Control Cable Connector (P1) to the Dual RadioCable Connector (P2), and tighten to jackscrews on P2.

8. Connect Power Cable, and Antenna, then install Master Radio Unit inmounting bracket.

9. After installing Slave Radio Unit in its mounting hardware, connectDual Radio Cable (P1), and tighten jackscrews. Be sure SW601setting on Slave Radio Unit is same as for Master Radio Unit. ConnectPower Cable and Antenna to Slave Radio.

10. Check Dual Radio operation, using operator's manual as test guide.

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5. In the "Multi-Radio" field of the PC programmer, select "Slave".Radio Units are now ready for vehicle installation.

6. Program normally. Do not include Extended Option features.

INSTALLATION INSTRUCTIONS FORFRONT/REMOTE MOUNT DUAL RADIOCONFIGURATION.

1. Plan the mounting locations of the two Radio Units. Note that themaximum cable length allowed between the two radios is two meters.Referring to Figure 36, run Dual Radio Cable (19B802554P10)between locations for Master and Slave Radio Units. Be sure to locatethe P2/P3 connector assembly at the Master Radio Unit.

2. After installing Master Radio Unit mounting hardware, connect theDual Radio Cable Connector (P3) to the Master Radio Unit. Tightenthe two jackscrews on P3. Next connect the Accessory Cable(19B802554P1 or P2) Connector (P1) to the Dual Radio CableConnector (P2), and tighten to jackscrews on P2.

3. Connect Microphone and Accessories. Refer to Accessory InstallationManual for proper connection of Accessories.

4. Connect Power Cable, and Antenna, then install Master Radio Unit inmounting bracket.

5. Connect "IGN A+" lead, if option is desired. Be sure internal SwitchSW601 is set properly. Refer to Page 20 of this manual for details.

6. After installing Slave Radio Unit in its mounting hardware, connectDual Radio Cable (P1), and tighten jackscrews. Be sure SW601setting on Slave Radio Unit is same as for Master Radio Unit. ConnectPower Cable and Antenna to Slave Radio.

7. Check Dual Radio operation, using Operator's Manual as test guide.

INSTALLATION INSTRUCTIONS FORREMOTE/REMOTE MOUNT DUAL RADIOCONFIGURATION.

1. Plan the mounting locations of the two Radio Units. Note that themaximum cable length allowed between the two radios is two meters.Referring to Figure 37, run Dual Radio Cable (19B802554P10)between locations for Master and Slave Radio Units. Be sure to locatethe P2/P3 connector assembly at the Master Radio Unit.

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Figure 3 - Cables

6

Table 1 - Orion Mobile Radio Optional AccessoriesOption Description Part Number

D2AN1M 900 MHz, 1/4 Wave Whip Antenna 19B801182P3D2AN1L 800 MHz 1/4 Wave Whip Antenna 19B209568P5D2AN1R VHF/UHF, 1/4 Wave Whip Antenna 19B209568P6D2CE1V Power Cable, 7.5 M 19B802622P1D2CE1W Accessory Cable, Front Mount 19B802554P1D2CE1X Accessory Cable, Rear Mount 19B802554P6D2CE1Y Control Cable, Remote Mount, 5.5 M 19B802554P3D2CE1Z Accessory Cable, Front Mount EURO 19B802554P11D2CE5R Extended Option Accessory Cable Front Mount 19B802554P2D2CE5S EXT Option Control Cable, Remote Mount, 5.5 M 19B802554P4D2CE5T EXT Option Accessory Cable, Remote Mount 19B802554P7D2CE5U EXT Option Accessory Cable, Front Mount, EURO 19B802554P12D2CE5V Control Cable, Remote Mount, EURO, 5.5 M 19B802554P13D2CE5W EXT Option Control Cable, Remote Mount, 5.5 M 19B802554P14D2CE5Z Dual Control Cable, Remote Mount, 9.0 M 19B802554P9D2CE7A Dual Radio Cable, Remote Mount, 2.0 M 19B802554P10D2CE7B Dual Control Cable, Remote Mount, 9.0 M, EUROD2CE7C Dual Radio Cable, Remote Mount, 2.0 M, EUROD2CE9A Power Cable, 7.5 M (For 50 W or less) 19B802622P3D2LS1F Speaker, GE Label 19A149590P1D2LS1H Speaker, ERICSSON Label 19A149590P11D2MA3J Mounting Bracket Kit, Remote Control Unit 344A4584G2D2MA3N Mounting Bracket Kit, Front Mount Radio 19B802672P1D2MA3R Mounting Bracket Kit, Remote Mount Radio 19B802673P1D2MA3W Mounting Bracket Kit, Remote Mount Radio, EURO 19B802672P1D2MA3X Cassette Mounting Bracket Kit, Front Mount, EURO 19B852366P1D2MC3W Microphone, GE LabelD2MC3Z Microphone, Ericsson LabelD2MK3E Keycap Kit, SCAN Control Unit 19C852359P101D2MK3F Keycap Kit, SYSTEM Control Unit 19C852359P102D2MN1A Microphone Hanger 7141414G2

PLANNING THE INSTALLATIONFigure 4 provides an example of a typical mobile radio installation.Before starting, plan the radio installation carefully so that it will be:

• safe for the operator and passengers• convenient for the operator to use• neat• protected from water damage• easy to service• out of the way of auto mechanics• out of the way of passengers

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DUAL RADIO UNITSThe Dual Radio feature can be configured either for two remote mountradio units or one front mount unit and one remote mount unit. In remotemount configurations the Control Unit is typically located in the vehiclecab, with the Radio Units located side-by-side in vehicle trunk. Infront/remote mount configurations the front mount unit is located in thevehicle cab, with the remote mount unit located in a convenient locationnearby. The remote/remote mount configuration is the preferredinstallation, since a separate control unit is required to program the remoteunit in a front/remote mount configuration.

The following Dual Radio Unit configurations are not allowed:

1. Any configuration using a DIN cassette mount.

2. Any installation where Extended Options are required from both RadioUnits. Extended Options are supported in one Radio Unit only.

PRE-INSTALLATION PROGRAMMINGPROCEDURE

All Radio Units in the Dual Radio configuration MUST BEPROGRAMMED prior to final installation. It is recommended that theunits be first programmed at a Service Center, then transferred to the user'sinstallation.

These configurations provide for a Master Radio Unit and a Slave RadioUnit. In the remote/remote mount configuration, the Master Radio Unit isalways the radio most directly connected to the Control Unit. In thefront/remote mount configuration, the Master Radio Unit is always the frontmount radio. Extended Options are allowed only in the Master Radio Unit.Programming each radio is straightforward, except that one radio isprogrammed as a Master, and one as a Slave.

1. Decide which Radio Unit shall be the Master Unit. Configure the radiofor programming as shown in the applicable service section manual.

2. In the "Multi-Radio" field of the PC programmer, select "Master".

3. Program unit normally. Include Extended Option features, ifpurchased.

4. Now configure the "Slave" Radio Unit for programming. Be sure touse the programming configuration for remote mount, and supply therequired control unit, if for a front/remote mount dual radioconfiguration.

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Figure 35 - Remote Mount Dual Control Cable 19B802554P9

(19B802554, Sh.7, Rev. 19)

7

Figure 4 - Typical Installation (Remote Mount Shown)

It is suggested that the radio be installed by one of the many authorizedGeneral Electric Service Stations located throughout the United States.These experienced service stations can provide a proper radio installationand make any final adjustments that may be needed.

WARNING

• Vehicular Electronics-Electronic fuel injection systems, electronicanti-skid braking systems, electronic cruise control systems, etc.,are typical of the types of electronic devices which may be proneto malfunction due to the lack of protection from radio frequencyenergy present when a radio is transmitting. If the vehicle containssuch equipment, consult the dealer to determine if such electronicequipment will perform normally when the radio is transmitting.

• For passenger safety, mount the radio securely so that the unit willnot break loose in the event of a collision. This is especiallyimportant in station wagons, vans and similar type installationswhere a loose radio could be extremely dangerous to the vehicleoccupants.

8

EQUIPMENT REQUIREDThe equipment required for installing the Orion Mobile Radio is listedbelow:

• Crimping Tool for fuse holder

• Electric drill for drilling mounting holes

• Drills and circle cutters as follows:

No. 31 (1/8-inch) drill

No. 27 (9/64-inch) drill

5/8-inch drill or circle cutter

3/4-inch circle cutter, hole saw or socket punch

• Phillips and flat-blade screwdrivers

• POZIDRIV driver

• No. 20 Torx driver

Torx is a registered trademark of CAMCAR Division TEXTRON, Inc.POZIDRIV is a registered trademark of Phillips International Company.

CAUTION

• Be careful to avoid damaging some vital part (fuel tank,transmission housing, etc.) of the vehicle when drilling mountingholes. Always check to see how far the mounting screws willextend below the mounting surface before installing.

• If pilot holes must be drilled, remove all metal shavings fromdrilling holes before installing screws.

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14. For Each Relay: Connect one end of a #18 AWG red wire to therelay, Pin 86. Cut the lead to length, and connect the other end to the1 amp fuse holder supplied. Use crimp on connectors supplied.Connect the other side of the 1 amp fuse holder to the A+ batterysource or a vehicle A+ fuse block. Use a #18 AWG red wire and aring lug supplied, if needed (Refer to Figure 34).

15. Check dual control operation, using the operator’s manual as a testguide. In the PC programming software, make sure the “DUALCONTROL SPEAKER is programmed ACTIVE HIGH .

Figure 34 - ORION Dual Control Unit Remote Mount/RemoteMount Installation Configuration

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3. After installing the Radio Unit in the normal fashion, connect thedual control cable connector (P3) to the Radio Unit. Tighten the twojackscrews on P3. Next, connect the Remote Control Cableconnector (P1) to the Dual Control Cable connector (P2), and tightenjackscrews on P2.

4. After installing the Main Control Unit in the normal fashion, connectthe Remote Control Cable (P2) to the Main Control Unit, and tightenjackscrews.

5. After installing the auxiliary control unit in the normal fashion,connect the Dual Control Cable (P1) to the Auxiliary Control Unit,and tighten jackscrews.

6. Connect the accessory cable (19B802554P6) to the AuxiliaryControl Unit. Connect either the accessory cable (19B802554P6) orthe extended option accessory cable (19B802554P7) to the MainControl Unit, as appropriate.

7. A yellow ignition sense lead is provided on each control cable. If the“Ignition Sense” feature is enabled on the Radio Unit, it isnecessary to connect only one of the yellow leads provided,whichever is convenient. Tape back the unused yellow lead. Seepage 20 for details.

8. Install the speakers in convient locations near each control unit.

9. Install a relay (19A149299P1) from the kits supplied at a locationnear the leads from each speaker. For mounting use the #8 X 3/4”sheetmetal screw and nutplate supplied with each kit.

10. At a convenient point cut one of the wires in each of the 2-wirespeaker cables, spread the leads, and strip the ends. (Crimp a 1/4” tabreceptacle to each end.

11. Main Control Unit Speaker: Connect the lead nearest the speaker toPin 87 of the relay. Connect the lead nearest the connector to Pin 30of the relay. Connect connector to the accessory cable P2 (Refer toFigure 34).

12. Auxiliary Control Unit Speaker: Connect the lead nearest thespeaker to Pin 87A of the relay. Connect the lead nearest theconnector to Pin 30 of the relay. Connect the connector to accessorycable P2 (Refer to Figure 34).

13. For Each Relay: Connect a #18 AWG black wire between the relay,Pin 85 and accessory cable P3-1 (labeled “OUT2” on schematicdiagrams in the service manual). Use a 1/4” tab receptacle on therelay side and a mating Molex connector and pins on the accessorycable side. Connect the mating Molex connector to the accessorycable P3 when finished (Refer to Figure 34).

9

INSTALLATION IN VEHICLES POWEREDBY LIQUEFIED (LP) GAS

Radio installation in vehicles powered by liquefied petroleum gaswith the LP gas container in the trunk or other sealed-off spacewithin the interior of the vehicle must conform to the National FireProtection Association Standard NFPA 58 which requires that:

• Space containing radio equipment shall be isolated by a seal from thespace containing the LP gas container and its fittings.

• Outside filling connections shall be used for the LP gas container.

• The LP gas container space shall be vented to the outside of thevehicle.

INSTALLATION

RUNNING CABLES

To assure the feasibility of the planned cable routings, it is suggested thatthe cables be run before mounting the radio. The Orion mobile radio maybe installed as a Front Mount, Remote Mount or Cassette Mount. Thetype of mount, the application and the options to be installed should beconsidered when planning the cable runs. Figures 5-12 provideInterconnection Diagrams for typical installations. Figures 5-12 shouldbe referenced throughout this manual and throughout the installation.

Be sure to leave some slack in each cable going to the radio so that theradio may be pulled out for servicing with the power applied and antennaattached. Coil any surplus cables and secure them out of the way. Try toroute the cables away from locations where they will be exposed to heat(exhaust pipes, mufflers, tailpipes, etc.), battery acid, sharp edges ormechanical damage or where they will be a nuisance to automobilemechanics, the driver or passengers. Keep wiring away from electroniccomputer modules, other electronic modules and ignition circuits to helpprevent interference to these components and radio equipment.

In addition, try to utilize existing holes in the firewall, trunk wall and thechannels above or beneath doors. Channels through door and windowcolumns that are convenient for running cables may also be used, unlessrigid or flexible conduit is to be installed for cable runs.

10

Figure 5 - Front Mount Basic Accessory Interconnections (USAModels Only)

Figure 6 - Front Mount Basic Accessory Interconnections (EUROModels Only)

Figure 7 - Front Mount Extended Option Accessory Interconnections(USA Models Only)

39

11. For each relay: Connect a #18 AWG black wire between the relay,Pin 85 and Accessory Cable P3-1 (labeled “OUT2” on the schematicdiagrams in the service manual). Use a 1/4” tab receptacle on therelay side and mating Molex connector and pins on the accessorycable side. Connect the mating Molex connector to the AccessoryCable P3 when finished (Refer to Figure 33).

12. For each relay: Connect a #18 AWG red wire to the relay, Pin 86.Cut to length, and connect to the 1 amp fuse holder supplied. Usecrimp on connectors supplied. Connect the other side of the 1 ampfuse holder to A+ battery source or vehicle A+ fuse block. Use #18AWG red wire and ring lug supplied., if needed (See Figure 33).

13. Check dual control operation, using operator’s manual as a testguide. In the PC programming software, make sure the “DUALCONTROL SPEAKER is programmed ACTIVE LOW .

Figure 33 - ORION Dual Control Unit Front Mount/Remote MountInstallation Configuration

INSTALLATION INSTRUCTIONS FOR REMOTEMOUNT DUAL CONTROL UNITS

1. Referring to Figure 34, run the Remote Control Cable(19B802554P3 or P4) between locations for the Radio Unit andMain Control Unit.

2. Run the Dual Control Cable (19B802554P9) between locations forthe Radio Unit and Auxiliary Control Unit. Be sure to locate theP2/P3 connector assembly at the radio unit.

38

INSTALLATION INSTRUCTIONS FOR FRONTMOUNT DUAL CONTROL UNITSThe Dual Control Unit feature is configured such that only one controlunit can be used for Extended Option accessories. All Extended Optionaccessories are connected through the Main Control Unit.

1. Referring to Figure 33, run the Dual Control Cable (19B802554P9)between locations for the Radio Unit and Auxiliary Control Unit. Besure to locate the P2/P3 connector assembly at the Radio Unit.

2. After installing Radio Unit mounting hardware in the normal fashion,connect the Dual Control Cable connector (P3) to the Radio Unit.Tighten the two jackscrews on P3. Next, connect the AccessoryCable (19B802554P1 or P2) Connector (P1) to the Dual ControlCable Connector (P2), and tighten the jackscrews on P2. Connect thepower cable, and install Radio Unit in mounting bracket.

3. After installing the Auxiliary Control Unit in the normal fashion,connect the Dual Control Cable (P1) to Auxiliary Control Unit, andtighten jackscrews.

4. Connect the Remote Mount Accessory Cable (19B802554P6) to theAuxiliary Control Unit.

5. A yellow Ignition Sense lead is provided on the Dual Control Cableand the Front Mount Accessory Cable. If the “Ignition Sense”feature is enabled on the Radio Unit, it is necessary to connect onlyone of the yellow leads provided, whichever is convenient. Tapeback the unused yellow lead (See Page 20 for details).

6. Install the Speakers in convenient locations near the Radio Unit andAuxiliary Control Unit.

7. Install a relay (19A149299P1) from the kits supplied at a locationnear the leads from each speaker. For mounting, use the #8 X 3/4”sheetmetal screw and nutplate supplied with each kit.

8. At a convenient point cut one of the wires in each of the 2-wirespeaker cables, spread the leads, and strip the ends. Crimp a 1/4” tabreceptacle to each end.

9. Radio Unit Speaker: Connect the lead nearest the speaker to Pin87A of the relay. Connect the lead nearest the connector to Pin 30 ofthe relay. Connect the connector to the Accessory Cable P2 (Refer toFigure 33).

10. Auxiliary Control Unit Speaker: Connect the lead nearest thespeaker to Pin 87 of the relay. Connect the lead nearest the connectorto Pin 30 of the relay. Connect the connector to the Accessory CableP2 (Refer to Figure 33).

11

Figure 8 - Front Mount Extended Option Accessory Interconnections(EURO Models Only)

Figure 9 - Remote Mount Basic Accessory Interconnections (USAModels Only)

Figure 10 - Remote Mount Basic Accessory Interconnections (EUROModels Only)

12

Figure 11 - Remote Mount Extended Option AccessoryInterconnections (USA Models Only)

Figure 12 - Remote Mount Extended Option AccessoryInterconnections (EURO Models Only)

Power Cable

The USA power cable (19B802622P1 or P3) consists of a red lead A+and a black lead A- connected to a molded 2-pin power connector andsupplied with ring terminals. The EURO power cable also consists of ared lead A+, a black lead A- and is terminated with ring terminals, but itis connected to P1 of the Accessory Cable or P1 of the Control Cable (inremote applications). To install the power cable:

1. Drill a 5/8-inch hole in the firewall for the cable run and insert therubber grommet. Run the cable through this grommet to the batterylocation. Secure the cable at several locations within the enginecompartment to prevent possible damage to cable.

2. Strip back the insulation approximately 3/8 of an inch from the endof the black lead. Slide one of the large heat shrink sleeves onto thewire and crimp a battery ring terminal onto this lead. Heat shrink thesleeve over the crimp connection. Connect the black lead directly tothe battery negative (-) or ground frame member.

3. Cut off 12-18 inches from the red lead. Strip back the insulationapproximately 3/8 of an inch on each end of the wires. Insert the

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Figure 32 - ORION Dual Control Unit PC ProgrammingConfiguration Remote Mount

36

PRE-INSTALLATION PROGRAMMINGPROCEDURE -- REMOTE MOUNT

The Radio and Control Units must be programmed in a sequentialprocedure, in order to provide each Control Unit with the properidentification code.

1. Configure the ORION Remote Mount Radio and Auxiliary ControlUnit with the PC Programming Assembly, as shown in Figure 32,Step 1. Program the radio with the following files:

Personality name <USERPERS> User’s personality fileRadio Code OGXXXXX Latest radio code file

(G13 or later vintage)

ADI Code <SAME>Radio Unit ID <SAME>ORION Keypad File <CUBMAP> Keypad definition for

Control Unit BORION CU ID CU B Must be Control Unit B

2. Now configure the Remote Mount Radio, the Main Control Unit, andthe Auxiliary Control Unit together with the PC ProgrammingAssembly, as shown in Figure 32, Step 2. Program this configurationwith the following files:

Personality Name <USERPERS> User’s personality fileRadio Code <SAME>ADI Code <SAME>Radio ID <SAME>ORION Keypad File <CUAMAP> Keypad definition for

Control Unit AORION CU ID CU A Must be Control Unit A

Note that the Main Control Unit has ID “A” and Auxiliary Control Unithas ID “B” in this configuration.

13

wire ends into the small openings at the end of each fuse holdersection and crimp a fuse connector to each wire. Prepare the otherend of the short wire in the same manner as in Step 2 and connect tothe positive (+) terminal of the battery.

NOTE

Do not install fuse into fuse holder until installation is completed andall connections have been checked.

NOTE

USA Power Cable 19B802622P3 is used only with radio with 50 wattsor less RF power output.

Figure 13 - Power Cable 19B802622P1 or P3 (USA Only)

Accessory Cable

Front Mount

The Basic Accessory Cable, at one end, consists of the basic accessoriesconnector (P3), the speaker connector (P2) and the ignition sense lead.At the other end is plug P1. P1 connects to the Option/Remote ControlConnector (ORCC) which is mounted on the back of the radio. TheEURO Accessory Cable also contains the red and black leads of thePower Cable.

NOTE: The EURO ORCC is the opposite gender from the USA ORCC.The Extended Option Accessory Cable is the same as the Basic Cablebut with the addition of the Extended Option Plug (P4). See Figures 14-17.

14

Figure 14 - USA Front Mount Standard Accessory Cable19B802554P1

(19B802554, Sh.1, Rev. 19)

35

Personality Name <USERPERS> User’s personality fileRadio Code OGXXXXX Latest radio code file

(G13 or later vintage)

ADI Code <SAME>Radio Unit ID <SAME>ORION Keypad File <CUBMAP> Keypad definition for

Control Unit B

ORION CU ID CU B Must be Control Unit B

2. Now configure the Front Mount Radio and the Auxiliary ControlUnit together with the PC Programming Assembly, as shown inFigure 31, Step 2. Program this configuration with the followingfiles:

Personality Name <USERPERS> User’s personality fileRadio Code <SAME>ADI Code <SAME>Radio ID <SAME>ORION Keypad Files <CUAMAP> Keypad definition for

Control Unit A

ORION CU ID CU A Must be Control Unit A

Note that the Main Control Unit has ID “B” and the Auxiliary ControlUnit has ID “A” in this configuration.

Figure 31 - ORION Dual Control Unit PC ProgrammingConfiguration

34

10. Recheck all connections and cables. Insert fuse into transmit fuseassembly.

Figure 30 - Handle Assembly In LOCKED Position

DUAL CONTROL UNITSThe Dual Control feature can be configured for either front mount or forremote mount Radio Units. Each configuration provides for a MainControl Unit and an Auxiliary Control Unit. In the front mountconfiguration, the Main Control Unit is on the Radio Unit itself (seeFigure 33), with the Auxiliary Control Unit located in a convenientlocation. In remote mount configuration the Main Control Unit istypically located in the vehicle cab, with the Auxiliary Control Unitlocated in a convenient location (see Figure 34).

All Radio Units and Control Units in the Dual Control Unit configurationMUST BE PROGRAMMED prior to final installation. It isrecommended that the units be first programmed at a Service Center, thentransferred to the user’s installation.

PRE-INSTALLATION PROGRAMMINGPROCEDURE --FRONT MOUNT

The Radio and Control Units must be programmed in a sequentialprocedure, in order to provide each Control Unit with the properidentification code.

1. Configure the ORION Front Mount Radio with the PC ProgrammingAssembly, as shown in Figure 31, Step 1. Program the radio with thefollowing files:

15

Figure 15 - EURO Front Mount Standard Accessory Cable19B802554P11

(19B802554, Sh.9, Rev. 19)

16

Figure 16 - USA Front Mount Extended Option Accessory Cable19B802554P2

(19B802554, Sh.2, Rev. 19)

33

8. Connect the extended option accessory plug P4 to the followingoptions (if used, see Figure 29):

• Mobile Data Terminal• Public Address (External Amplifier)• External Microphone• External Tone Encoder• External Tone Decoder• Output (User Defined)• Input (User Defined)

CAUTION

Refer to accessory manual supplement for details regarding the extendedoptions listed above. DO NOT CONNECT DIRECTLY TO A PC ORDATA TERMINAL. DAMAGE COULD RESULT!!!

9. With the handle assembly in the UNLOCKED position (out in frontof the control unit), insert the radio into the cassette assembly. Slidethe radio into the cassette assembly until the back of the radio meetsthe back of the cassette assembly.

NOTE

Caution should be used while engaging the radio in the cassette the firstfew times until the cabling in the cassette mount assembly has had anopportunity to work into its permanent location. To insure proper firsttime engagement, the following procedure should be used:

Insert radio into cassette mount opening and slide in until you feel somespring resistance. Holding the handle, jiggle the radio a bit to give it achance to find the connectors. Then engage the radio handle in the sheetmetal hooks which protrude from the lower corners of the cassettemount casing. Rotate the handle upward to fully engage the radio. SeeFigure 30. DO NOT FORCE THE CONNECTOR ENGAGEMENTportion of the travel.

If the radio does not go in using this procedure, a large flat bladescrewdriver may be used to re-position the 37 pin connector slightly toassist the first time engagement.

32

Figure 29 - Cassette Assembly Schematic Diagram

(19C852366, Sh.2, Rev.1)

17

Figure 17 - EURO Front Mount Extended Option Accessory Cable19B802554P12

(19B802554, Sh.10, Rev. 19)

18

Remote Mount

The Basic Accessory Cable, at one end, consists of the basic accessoriesconnector (P3) and the speaker connector (P2). At the other end is theplug P1. P1 will connect to the Option Connector (OPT) which ismounted on the back of the Radio Interface Adapter (RIA). TheExtended Option Accessory Cable is the same as the Basic Cable but withthe addition of the Extended Option Plug (P4). See Figures 18 and 19.

Figure 18 - Remote Mount Standard Accessory Cable 19B802554P6(19B802554, Sh.5, Rev. 19)

31

Cassette Assembly Mounting

1. Insert the cassette assembly in the mounting location. Secure thecables with the sheet metal screws and retaining straps provided.

2. Secure the back of the cassette assembly using the mounting stud(located at the back of the cassette assembly), No. 6 flat washer, No.6 split lock washer and No. 6 wing nut.

3. Several tabs are located on the top, bottom and sides of the cassetteassembly. These tabs are conveniently located near the front of theassembly and may be bent out as needed to further secure thecassette assembly to the vehicle.

4. Next install the Handle Assembly:

a. Turn the radio upside down. Remove the two small machinescrews on the bottom of the radio, near the front. Use upwardpressure on screws to engage captivated threads for removal.

b. Using the machine screws and flat washers provided with thehandle assembly, attach the handle to the bottom of the radio.The two holes on the handle should align with the two holes onthe radio created by step (a). Once installed, the rubber handleshould rotate freely from over top of the radio to just out in frontof the control unit (approximately 90 degrees). Be sure totorque the two mounting screws within 6.5 to 8.25 in/lb limits.

5. Connect the antenna coaxial cable to the cassette mounting assemblyrear connector.

6. Connect the Power leads and the Ignition Sense leads as described inprevious sections. See Figure 29.

7. Connect the speaker cable connector P2 to the speaker and the basicaccessory connector P3 to the following options (if used, see Figure29):

Option Plug & PinExt. Hookswitch P3-3 (HOT)

P3-6 (GND)

Foot Switch P3-5 (HOT)P3-2 (GND)

Horn Relay P3-1 (HOT)

P3-4 (GND)

30

Figure 27 - Remote Mounting Bracket Installation

Cassette Mounting (EURO ONLY)

The cassette mounting assembly is designed to mount in a standard DINspace in the instrument panel or console. This mounting permits rapidinsertion and removal of the radio unit from the vehicle. All connectionsare made through a quick disconnect connector at the rear of the cassettemounting assembly to the radio unit. This connector is part of thecassette assembly. The cassette assembly is shown in Figure 28.

Figure 28 - Cassette Assembly

Top Mount

Bottom Mount

19

Figure 19 - Remote Mount Extended Option Accessory Cable19B802554P7

(19B802554, Sh.6, Rev. 19)

20

Ignition Sense (All Applications)

NOTE

• The radio as shipped from the factory has the "ignition sense"feature disabled. As such the radio will be powered ON or OFF asdetermined by the front panel ON/OFF/VOLUME control only(assuming A+ and A- are connected). If it is desired to enable the"ignition sense" feature, open top cover of radio and remove shieldfrom logic PWB. Slide switch SW601 from position 3-2 to 1-2.Replace shield and top cover. Be sure to apply correct torque toscrews holding top cover in place. See Maintenance Manual.

• The "Accessory" point should drop to ZERO volts when crankingthe engine and return to +12 volts after the engine is started. If apoint is chosen that drops to a voltage between zero and +12 volts,the radio may execute a power-up cycle several times during startup. It is recommended that the terminal be measured with avoltmeter to be sure it shuts off (goes to zero volts) during thecranking of the engine.

The fuse holder must be attached to the yellow sense lead along with thering terminal as follows:

1. Cut the yellow sense lead approximately 6-12" from the end that willbe connected to the power source.

2. Strip the insulation from each end of the short lead and from the endof the long lead at least 3/8".

3. Insert the stripped end of the long lead and one end of the short leadinto the narrow end of each fuse holder half.

4. Crimp the leads in the fuse holder halves with a crimping tool.

5. Insert the 3 amp fuse into one end of the fuse holder and join the twofuse holder halves firmly together.

6. Attach the ring terminal to the end of the short lead and connect thislead to the ignition "ON" sense point [preferably an "Accessory"point (in the vehicle fuse panel) that is switched on when the vehicleignition switch is in the ACCESSORY and RUN positions].

29

Remote Mount Installation

The bracket shown in Figure 27 is used for Remote Mounting (USAOnly). In some applications the bracket shown in Figure 26 can also beused for Remote Mounting. The following instructions are for a RemoteMount installation using the bracket shown in Figure 27.

1. Using the bracket as a template, mark and drill the mounting holesusing a No. 27 drill. Be sure to leave enough room at the rear of theradio unit for the cable connections.

2. Secure the Mounting bracket using four 1/4"-14 x 3/4" sheet metalscrews (use 1/4"-14 x 1" if needed.) The bracket can be usedmounted so that it is either above or below the radio for the user'sconvenience.

3. Slide the radio unit into the bracket by aligning bracket guides withgrooves on each side of radio (rear of radio should be inserted first).Slide radio back until screw holes in front of bracket align withscrew holes in side of radio. See Figure 27.

4. Secure radio to the bracket with two M4 x 10 mm socket head screwsprovided.

5. Connect antenna coaxial cable to antenna connector (TNC).

6. Connect remote control cable connector P1 to the ORCC connectoron the radio unit and secure with the two captive screws.

7. Connect other end of remote control cable to the remote controlcable connector (RCCC) on the remote control unit.

8. Connect remote mount accessory cable connector P1 to the optionconnector (OPT) on control unit. Then connect the speaker toconnector P2 and accessory connector P3 to any options(hookswitch, etc.). If connector P3 is not used, insulate and tie backto main cable.

9. Recheck all connections and cables. Insert fuse into transmit fuseassembly.

28

Figure 26 - Mounting Bracket Installation

6. Connect front mount accessory cable connector P2 to speaker cableconnector.

7. Connect power cable to power connector on rear of radio unit andsecure with the two captive screws to the radio unit.

8. Connect microphone connector to connector on front panel andsecure with captive screw.

NOTE

Do not torque microphone connector screw greater than 2 in-lb.Alternatively, finger tight plus 1/4 turn is acceptable.

9. If there are no other accessory connections, tie back plug P3 to maincable.

10. Recheck all connections before inserting fuse into transmit fuseassembly.

Top Mount

Bottom Mount

21

CAUTION

Certain problems may be encountered when accessory equipment isconnected to the ignition or accessory lines of the vehicle, where theselines may have large filter capacitors and a leakage path present. If theradio does not turn off within a reasonable amount of time after theignition is turned off, first try a different accessory or ignition sensepick up point in the vehicle. Many vehicles have more than one circuitthat is switched by the ignition switch, and one may be available thatdoes not have large filter capacitors or a leakage path present.

If a different pickup point cannot be found, then add a 470-ohm, 1-wattresistor from the ignition sense pick point to ground. This willdischarge the capacitor(s) or reduce the leakage voltage to a low value.Current drain through this resistor will be minimal (less than 0.03A)when the ignition is switched on.

Control Cable (Remote Mount Only)

The Control Cable is used to connect the Control Unit (through the RIA)to the Radio Transceiver in remote applications. Plug P2, at one end,connects to the Remote Control Cable Connector (RCCC) which ismounted on the back of the RIA. The Ignition Sense wire is also part ofP2. The other end of the Control Cable (P1) connects to the ORCCwhich is mounted on the back of the radio. P1 of the EURO ControlCable also contains the Power Cable leads. See Figures 20-23.

CONTROL UNIT MOUNTING (REMOTEAPPLICATIONS ONLY)

1. Using the bracket as a template, mark and drill the mounting holes.Be sure to leave enough room at the rear of the control unit for thecable connector. Refer to Figure 24 for control unit mounting bracketinstallation.

2. Secure the mounting bracket using the four No. 10 x 3/4 self-tappingscrews supplied (use No. 10 x 1-1/2 if needed.).

3. Secure the control unit to the bracket with the two 1/4-20 x 5/8 hexhead screws and lock washers provided.

22

Figure 20 - USA Remote Control Cable 19B802554P3(19B802554, Sh.3, Rev. 19)

27

Figure 25 - Speaker Mounting

RADIO MOUNTING AND FINAL HOOK-UP

Front Mount

Typically the bracket shown in Figure 26 is used for Front Mountapplications. The bracket can be mounted so that it is either above orbelow the radio for the user's convenience. The bracket pictured inFigure 24 can also be used for Remote Mount application but is notrecommended for 110 watt VHF radios or 100 watt UHF radios.The following instructions are for a Front Mount installation using thebracket shown in Figure 26.

1. Use the supplied mounting bracket as a template to locate theposition for each of the drill holes. Be sure to leave enough room atthe front and rear of the radio for cable connections. Drill No. 27(9/64) pilot holes.

2. Mount bracket with four 1/4"-14 x 3/4" sheet metal screws (use 1/4"-14 x 1-1/2" screws if needed).

3. Place radio into mounting bracket and secure with the four M4 x 10mm hex head screws, M4 flat washers and M4 lock washerssupplied. No. 20 Torx.

4. Connect antenna coaxial cable to antenna connector (TNC).

5. Connect front mount accessory cable connector P1 to theOption/Remote Control Connector (ORCC) and secure with the twocaptive screws in the connector to the radio.

26

Figure 24 - Control Unit Mounting Bracket Installation

SPEAKER D2LS1F

The speaker kit includes the speaker, mounting bracket and connectingcable. Mount the speaker so it is directed to the operator but does notpresent a hazard in the event of an accident. The speaker may be mountedon the lower edge of the instrument panel, the firewall or above thewindshield in some trucks.

1. Use the mounting bracket as a template for locating the mountingholes and mount the speaker as shown in Figure 25.

2. Refer to the applicable installation procedures for connection of thespeaker to the accessory cable.

MICROPHONE HANGER AND/OR HOOKSWITCHMOUNTING

The microphone hanger or hookswitch should be mounted in a locationconvenient to the operator where it will not interfere with the safeoperation of the vehicle or be a hazard to the vehicle passengers. Thehanger or hookswitch is designed to be mounted with the open end of themounting button slot pointed upward. Use the hanger or hookswitch as atemplate to mark and drill the mounting holes. Mount the hanger orhookswitch with the self-tapping screws provided.

Top Mount Bottom Mount

23

Figure 21 - USA Remote Extended Option Control Cable19B802554P4

(19B802554, Sh.4, Rev. 19)

24

Figure 22 - USA Extended Options Remote Control Cable19B802554P13

(19B802554, Sh.11, Rev. 19)

25

Figure 23 - EURO Extended Options Remote Control Cable19B802554P14

(19B802554, Sh.12, Rev. 19)

24

Figure 22 - USA Extended Options Remote Control Cable19B802554P13

(19B802554, Sh.11, Rev. 19)

25

Figure 23 - EURO Extended Options Remote Control Cable19B802554P14

(19B802554, Sh.12, Rev. 19)

26

Figure 24 - Control Unit Mounting Bracket Installation

SPEAKER D2LS1F

The speaker kit includes the speaker, mounting bracket and connectingcable. Mount the speaker so it is directed to the operator but does notpresent a hazard in the event of an accident. The speaker may be mountedon the lower edge of the instrument panel, the firewall or above thewindshield in some trucks.

1. Use the mounting bracket as a template for locating the mountingholes and mount the speaker as shown in Figure 25.

2. Refer to the applicable installation procedures for connection of thespeaker to the accessory cable.

MICROPHONE HANGER AND/OR HOOKSWITCHMOUNTING

The microphone hanger or hookswitch should be mounted in a locationconvenient to the operator where it will not interfere with the safeoperation of the vehicle or be a hazard to the vehicle passengers. Thehanger or hookswitch is designed to be mounted with the open end of themounting button slot pointed upward. Use the hanger or hookswitch as atemplate to mark and drill the mounting holes. Mount the hanger orhookswitch with the self-tapping screws provided.

Top Mount Bottom Mount

23

Figure 21 - USA Remote Extended Option Control Cable19B802554P4

(19B802554, Sh.4, Rev. 19)

22

Figure 20 - USA Remote Control Cable 19B802554P3(19B802554, Sh.3, Rev. 19)

27

Figure 25 - Speaker Mounting

RADIO MOUNTING AND FINAL HOOK-UP

Front Mount

Typically the bracket shown in Figure 26 is used for Front Mountapplications. The bracket can be mounted so that it is either above orbelow the radio for the user's convenience. The bracket pictured inFigure 24 can also be used for Remote Mount application but is notrecommended for 110 watt VHF radios or 100 watt UHF radios.The following instructions are for a Front Mount installation using thebracket shown in Figure 26.

1. Use the supplied mounting bracket as a template to locate theposition for each of the drill holes. Be sure to leave enough room atthe front and rear of the radio for cable connections. Drill No. 27(9/64) pilot holes.

2. Mount bracket with four 1/4"-14 x 3/4" sheet metal screws (use 1/4"-14 x 1-1/2" screws if needed).

3. Place radio into mounting bracket and secure with the four M4 x 10mm hex head screws, M4 flat washers and M4 lock washerssupplied. No. 20 Torx.

4. Connect antenna coaxial cable to antenna connector (TNC).

5. Connect front mount accessory cable connector P1 to theOption/Remote Control Connector (ORCC) and secure with the twocaptive screws in the connector to the radio.

28

Figure 26 - Mounting Bracket Installation

6. Connect front mount accessory cable connector P2 to speaker cableconnector.

7. Connect power cable to power connector on rear of radio unit andsecure with the two captive screws to the radio unit.

8. Connect microphone connector to connector on front panel andsecure with captive screw.

NOTE

Do not torque microphone connector screw greater than 2 in-lb.Alternatively, finger tight plus 1/4 turn is acceptable.

9. If there are no other accessory connections, tie back plug P3 to maincable.

10. Recheck all connections before inserting fuse into transmit fuseassembly.

Top Mount

Bottom Mount

21

CAUTION

Certain problems may be encountered when accessory equipment isconnected to the ignition or accessory lines of the vehicle, where theselines may have large filter capacitors and a leakage path present. If theradio does not turn off within a reasonable amount of time after theignition is turned off, first try a different accessory or ignition sensepick up point in the vehicle. Many vehicles have more than one circuitthat is switched by the ignition switch, and one may be available thatdoes not have large filter capacitors or a leakage path present.

If a different pickup point cannot be found, then add a 470-ohm, 1-wattresistor from the ignition sense pick point to ground. This willdischarge the capacitor(s) or reduce the leakage voltage to a low value.Current drain through this resistor will be minimal (less than 0.03A)when the ignition is switched on.

Control Cable (Remote Mount Only)

The Control Cable is used to connect the Control Unit (through the RIA)to the Radio Transceiver in remote applications. Plug P2, at one end,connects to the Remote Control Cable Connector (RCCC) which ismounted on the back of the RIA. The Ignition Sense wire is also part ofP2. The other end of the Control Cable (P1) connects to the ORCCwhich is mounted on the back of the radio. P1 of the EURO ControlCable also contains the Power Cable leads. See Figures 20-23.

CONTROL UNIT MOUNTING (REMOTEAPPLICATIONS ONLY)

1. Using the bracket as a template, mark and drill the mounting holes.Be sure to leave enough room at the rear of the control unit for thecable connector. Refer to Figure 24 for control unit mounting bracketinstallation.

2. Secure the mounting bracket using the four No. 10 x 3/4 self-tappingscrews supplied (use No. 10 x 1-1/2 if needed.).

3. Secure the control unit to the bracket with the two 1/4-20 x 5/8 hexhead screws and lock washers provided.

20

Ignition Sense (All Applications)

NOTE

• The radio as shipped from the factory has the "ignition sense"feature disabled. As such the radio will be powered ON or OFF asdetermined by the front panel ON/OFF/VOLUME control only(assuming A+ and A- are connected). If it is desired to enable the"ignition sense" feature, open top cover of radio and remove shieldfrom logic PWB. Slide switch SW601 from position 3-2 to 1-2.Replace shield and top cover. Be sure to apply correct torque toscrews holding top cover in place. See Maintenance Manual.

• The "Accessory" point should drop to ZERO volts when crankingthe engine and return to +12 volts after the engine is started. If apoint is chosen that drops to a voltage between zero and +12 volts,the radio may execute a power-up cycle several times during startup. It is recommended that the terminal be measured with avoltmeter to be sure it shuts off (goes to zero volts) during thecranking of the engine.

The fuse holder must be attached to the yellow sense lead along with thering terminal as follows:

1. Cut the yellow sense lead approximately 6-12" from the end that willbe connected to the power source.

2. Strip the insulation from each end of the short lead and from the endof the long lead at least 3/8".

3. Insert the stripped end of the long lead and one end of the short leadinto the narrow end of each fuse holder half.

4. Crimp the leads in the fuse holder halves with a crimping tool.

5. Insert the 3 amp fuse into one end of the fuse holder and join the twofuse holder halves firmly together.

6. Attach the ring terminal to the end of the short lead and connect thislead to the ignition "ON" sense point [preferably an "Accessory"point (in the vehicle fuse panel) that is switched on when the vehicleignition switch is in the ACCESSORY and RUN positions].

29

Remote Mount Installation

The bracket shown in Figure 27 is used for Remote Mounting (USAOnly). In some applications the bracket shown in Figure 26 can also beused for Remote Mounting. The following instructions are for a RemoteMount installation using the bracket shown in Figure 27.

1. Using the bracket as a template, mark and drill the mounting holesusing a No. 27 drill. Be sure to leave enough room at the rear of theradio unit for the cable connections.

2. Secure the Mounting bracket using four 1/4"-14 x 3/4" sheet metalscrews (use 1/4"-14 x 1" if needed.) The bracket can be usedmounted so that it is either above or below the radio for the user'sconvenience.

3. Slide the radio unit into the bracket by aligning bracket guides withgrooves on each side of radio (rear of radio should be inserted first).Slide radio back until screw holes in front of bracket align withscrew holes in side of radio. See Figure 27.

4. Secure radio to the bracket with two M4 x 10 mm socket head screwsprovided.

5. Connect antenna coaxial cable to antenna connector (TNC).

6. Connect remote control cable connector P1 to the ORCC connectoron the radio unit and secure with the two captive screws.

7. Connect other end of remote control cable to the remote controlcable connector (RCCC) on the remote control unit.

8. Connect remote mount accessory cable connector P1 to the optionconnector (OPT) on control unit. Then connect the speaker toconnector P2 and accessory connector P3 to any options(hookswitch, etc.). If connector P3 is not used, insulate and tie backto main cable.

9. Recheck all connections and cables. Insert fuse into transmit fuseassembly.

30

Figure 27 - Remote Mounting Bracket Installation

Cassette Mounting (EURO ONLY)

The cassette mounting assembly is designed to mount in a standard DINspace in the instrument panel or console. This mounting permits rapidinsertion and removal of the radio unit from the vehicle. All connectionsare made through a quick disconnect connector at the rear of the cassettemounting assembly to the radio unit. This connector is part of thecassette assembly. The cassette assembly is shown in Figure 28.

Figure 28 - Cassette Assembly

Top Mount

Bottom Mount

19

Figure 19 - Remote Mount Extended Option Accessory Cable19B802554P7

(19B802554, Sh.6, Rev. 19)

18

Remote Mount

The Basic Accessory Cable, at one end, consists of the basic accessoriesconnector (P3) and the speaker connector (P2). At the other end is theplug P1. P1 will connect to the Option Connector (OPT) which ismounted on the back of the Radio Interface Adapter (RIA). TheExtended Option Accessory Cable is the same as the Basic Cable but withthe addition of the Extended Option Plug (P4). See Figures 18 and 19.

Figure 18 - Remote Mount Standard Accessory Cable 19B802554P6(19B802554, Sh.5, Rev. 19)

31

Cassette Assembly Mounting

1. Insert the cassette assembly in the mounting location. Secure thecables with the sheet metal screws and retaining straps provided.

2. Secure the back of the cassette assembly using the mounting stud(located at the back of the cassette assembly), No. 6 flat washer, No.6 split lock washer and No. 6 wing nut.

3. Several tabs are located on the top, bottom and sides of the cassetteassembly. These tabs are conveniently located near the front of theassembly and may be bent out as needed to further secure thecassette assembly to the vehicle.

4. Next install the Handle Assembly:

a. Turn the radio upside down. Remove the two small machinescrews on the bottom of the radio, near the front. Use upwardpressure on screws to engage captivated threads for removal.

b. Using the machine screws and flat washers provided with thehandle assembly, attach the handle to the bottom of the radio.The two holes on the handle should align with the two holes onthe radio created by step (a). Once installed, the rubber handleshould rotate freely from over top of the radio to just out in frontof the control unit (approximately 90 degrees). Be sure totorque the two mounting screws within 6.5 to 8.25 in/lb limits.

5. Connect the antenna coaxial cable to the cassette mounting assemblyrear connector.

6. Connect the Power leads and the Ignition Sense leads as described inprevious sections. See Figure 29.

7. Connect the speaker cable connector P2 to the speaker and the basicaccessory connector P3 to the following options (if used, see Figure29):

Option Plug & PinExt. Hookswitch P3-3 (HOT)

P3-6 (GND)

Foot Switch P3-5 (HOT)P3-2 (GND)

Horn Relay P3-1 (HOT)

P3-4 (GND)

32

Figure 29 - Cassette Assembly Schematic Diagram

(19C852366, Sh.2, Rev.1)

17

Figure 17 - EURO Front Mount Extended Option Accessory Cable19B802554P12

(19B802554, Sh.10, Rev. 19)

16

Figure 16 - USA Front Mount Extended Option Accessory Cable19B802554P2

(19B802554, Sh.2, Rev. 19)

33

8. Connect the extended option accessory plug P4 to the followingoptions (if used, see Figure 29):

• Mobile Data Terminal• Public Address (External Amplifier)• External Microphone• External Tone Encoder• External Tone Decoder• Output (User Defined)• Input (User Defined)

CAUTION

Refer to accessory manual supplement for details regarding the extendedoptions listed above. DO NOT CONNECT DIRECTLY TO A PC ORDATA TERMINAL. DAMAGE COULD RESULT!!!

9. With the handle assembly in the UNLOCKED position (out in frontof the control unit), insert the radio into the cassette assembly. Slidethe radio into the cassette assembly until the back of the radio meetsthe back of the cassette assembly.

NOTE

Caution should be used while engaging the radio in the cassette the firstfew times until the cabling in the cassette mount assembly has had anopportunity to work into its permanent location. To insure proper firsttime engagement, the following procedure should be used:

Insert radio into cassette mount opening and slide in until you feel somespring resistance. Holding the handle, jiggle the radio a bit to give it achance to find the connectors. Then engage the radio handle in the sheetmetal hooks which protrude from the lower corners of the cassettemount casing. Rotate the handle upward to fully engage the radio. SeeFigure 30. DO NOT FORCE THE CONNECTOR ENGAGEMENTportion of the travel.

If the radio does not go in using this procedure, a large flat bladescrewdriver may be used to re-position the 37 pin connector slightly toassist the first time engagement.

34

10. Recheck all connections and cables. Insert fuse into transmit fuseassembly.

Figure 30 - Handle Assembly In LOCKED Position

DUAL CONTROL UNITSThe Dual Control feature can be configured for either front mount or forremote mount Radio Units. Each configuration provides for a MainControl Unit and an Auxiliary Control Unit. In the front mountconfiguration, the Main Control Unit is on the Radio Unit itself (seeFigure 33), with the Auxiliary Control Unit located in a convenientlocation. In remote mount configuration the Main Control Unit istypically located in the vehicle cab, with the Auxiliary Control Unitlocated in a convenient location (see Figure 34).

All Radio Units and Control Units in the Dual Control Unit configurationMUST BE PROGRAMMED prior to final installation. It isrecommended that the units be first programmed at a Service Center, thentransferred to the user’s installation.

PRE-INSTALLATION PROGRAMMINGPROCEDURE --FRONT MOUNT

The Radio and Control Units must be programmed in a sequentialprocedure, in order to provide each Control Unit with the properidentification code.

1. Configure the ORION Front Mount Radio with the PC ProgrammingAssembly, as shown in Figure 31, Step 1. Program the radio with thefollowing files:

15

Figure 15 - EURO Front Mount Standard Accessory Cable19B802554P11

(19B802554, Sh.9, Rev. 19)

14

Figure 14 - USA Front Mount Standard Accessory Cable19B802554P1

(19B802554, Sh.1, Rev. 19)

35

Personality Name <USERPERS> User’s personality fileRadio Code OGXXXXX Latest radio code file

(G13 or later vintage)

ADI Code <SAME>Radio Unit ID <SAME>ORION Keypad File <CUBMAP> Keypad definition for

Control Unit B

ORION CU ID CU B Must be Control Unit B

2. Now configure the Front Mount Radio and the Auxiliary ControlUnit together with the PC Programming Assembly, as shown inFigure 31, Step 2. Program this configuration with the followingfiles:

Personality Name <USERPERS> User’s personality fileRadio Code <SAME>ADI Code <SAME>Radio ID <SAME>ORION Keypad Files <CUAMAP> Keypad definition for

Control Unit A

ORION CU ID CU A Must be Control Unit A

Note that the Main Control Unit has ID “B” and the Auxiliary ControlUnit has ID “A” in this configuration.

Figure 31 - ORION Dual Control Unit PC ProgrammingConfiguration

36

PRE-INSTALLATION PROGRAMMINGPROCEDURE -- REMOTE MOUNT

The Radio and Control Units must be programmed in a sequentialprocedure, in order to provide each Control Unit with the properidentification code.

1. Configure the ORION Remote Mount Radio and Auxiliary ControlUnit with the PC Programming Assembly, as shown in Figure 32,Step 1. Program the radio with the following files:

Personality name <USERPERS> User’s personality fileRadio Code OGXXXXX Latest radio code file

(G13 or later vintage)

ADI Code <SAME>Radio Unit ID <SAME>ORION Keypad File <CUBMAP> Keypad definition for

Control Unit BORION CU ID CU B Must be Control Unit B

2. Now configure the Remote Mount Radio, the Main Control Unit, andthe Auxiliary Control Unit together with the PC ProgrammingAssembly, as shown in Figure 32, Step 2. Program this configurationwith the following files:

Personality Name <USERPERS> User’s personality fileRadio Code <SAME>ADI Code <SAME>Radio ID <SAME>ORION Keypad File <CUAMAP> Keypad definition for

Control Unit AORION CU ID CU A Must be Control Unit A

Note that the Main Control Unit has ID “A” and Auxiliary Control Unithas ID “B” in this configuration.

13

wire ends into the small openings at the end of each fuse holdersection and crimp a fuse connector to each wire. Prepare the otherend of the short wire in the same manner as in Step 2 and connect tothe positive (+) terminal of the battery.

NOTE

Do not install fuse into fuse holder until installation is completed andall connections have been checked.

NOTE

USA Power Cable 19B802622P3 is used only with radio with 50 wattsor less RF power output.

Figure 13 - Power Cable 19B802622P1 or P3 (USA Only)

Accessory Cable

Front Mount

The Basic Accessory Cable, at one end, consists of the basic accessoriesconnector (P3), the speaker connector (P2) and the ignition sense lead.At the other end is plug P1. P1 connects to the Option/Remote ControlConnector (ORCC) which is mounted on the back of the radio. TheEURO Accessory Cable also contains the red and black leads of thePower Cable.

NOTE: The EURO ORCC is the opposite gender from the USA ORCC.The Extended Option Accessory Cable is the same as the Basic Cablebut with the addition of the Extended Option Plug (P4). See Figures 14-17.

12

Figure 11 - Remote Mount Extended Option AccessoryInterconnections (USA Models Only)

Figure 12 - Remote Mount Extended Option AccessoryInterconnections (EURO Models Only)

Power Cable

The USA power cable (19B802622P1 or P3) consists of a red lead A+and a black lead A- connected to a molded 2-pin power connector andsupplied with ring terminals. The EURO power cable also consists of ared lead A+, a black lead A- and is terminated with ring terminals, but itis connected to P1 of the Accessory Cable or P1 of the Control Cable (inremote applications). To install the power cable:

1. Drill a 5/8-inch hole in the firewall for the cable run and insert therubber grommet. Run the cable through this grommet to the batterylocation. Secure the cable at several locations within the enginecompartment to prevent possible damage to cable.

2. Strip back the insulation approximately 3/8 of an inch from the endof the black lead. Slide one of the large heat shrink sleeves onto thewire and crimp a battery ring terminal onto this lead. Heat shrink thesleeve over the crimp connection. Connect the black lead directly tothe battery negative (-) or ground frame member.

3. Cut off 12-18 inches from the red lead. Strip back the insulationapproximately 3/8 of an inch on each end of the wires. Insert the

37

Figure 32 - ORION Dual Control Unit PC ProgrammingConfiguration Remote Mount

38

INSTALLATION INSTRUCTIONS FOR FRONTMOUNT DUAL CONTROL UNITSThe Dual Control Unit feature is configured such that only one controlunit can be used for Extended Option accessories. All Extended Optionaccessories are connected through the Main Control Unit.

1. Referring to Figure 33, run the Dual Control Cable (19B802554P9)between locations for the Radio Unit and Auxiliary Control Unit. Besure to locate the P2/P3 connector assembly at the Radio Unit.

2. After installing Radio Unit mounting hardware in the normal fashion,connect the Dual Control Cable connector (P3) to the Radio Unit.Tighten the two jackscrews on P3. Next, connect the AccessoryCable (19B802554P1 or P2) Connector (P1) to the Dual ControlCable Connector (P2), and tighten the jackscrews on P2. Connect thepower cable, and install Radio Unit in mounting bracket.

3. After installing the Auxiliary Control Unit in the normal fashion,connect the Dual Control Cable (P1) to Auxiliary Control Unit, andtighten jackscrews.

4. Connect the Remote Mount Accessory Cable (19B802554P6) to theAuxiliary Control Unit.

5. A yellow Ignition Sense lead is provided on the Dual Control Cableand the Front Mount Accessory Cable. If the “Ignition Sense”feature is enabled on the Radio Unit, it is necessary to connect onlyone of the yellow leads provided, whichever is convenient. Tapeback the unused yellow lead (See Page 20 for details).

6. Install the Speakers in convenient locations near the Radio Unit andAuxiliary Control Unit.

7. Install a relay (19A149299P1) from the kits supplied at a locationnear the leads from each speaker. For mounting, use the #8 X 3/4”sheetmetal screw and nutplate supplied with each kit.

8. At a convenient point cut one of the wires in each of the 2-wirespeaker cables, spread the leads, and strip the ends. Crimp a 1/4” tabreceptacle to each end.

9. Radio Unit Speaker: Connect the lead nearest the speaker to Pin87A of the relay. Connect the lead nearest the connector to Pin 30 ofthe relay. Connect the connector to the Accessory Cable P2 (Refer toFigure 33).

10. Auxiliary Control Unit Speaker: Connect the lead nearest thespeaker to Pin 87 of the relay. Connect the lead nearest the connectorto Pin 30 of the relay. Connect the connector to the Accessory CableP2 (Refer to Figure 33).

11

Figure 8 - Front Mount Extended Option Accessory Interconnections(EURO Models Only)

Figure 9 - Remote Mount Basic Accessory Interconnections (USAModels Only)

Figure 10 - Remote Mount Basic Accessory Interconnections (EUROModels Only)

10

Figure 5 - Front Mount Basic Accessory Interconnections (USAModels Only)

Figure 6 - Front Mount Basic Accessory Interconnections (EUROModels Only)

Figure 7 - Front Mount Extended Option Accessory Interconnections(USA Models Only)

39

11. For each relay: Connect a #18 AWG black wire between the relay,Pin 85 and Accessory Cable P3-1 (labeled “OUT2” on the schematicdiagrams in the service manual). Use a 1/4” tab receptacle on therelay side and mating Molex connector and pins on the accessorycable side. Connect the mating Molex connector to the AccessoryCable P3 when finished (Refer to Figure 33).

12. For each relay: Connect a #18 AWG red wire to the relay, Pin 86.Cut to length, and connect to the 1 amp fuse holder supplied. Usecrimp on connectors supplied. Connect the other side of the 1 ampfuse holder to A+ battery source or vehicle A+ fuse block. Use #18AWG red wire and ring lug supplied., if needed (See Figure 33).

13. Check dual control operation, using operator’s manual as a testguide. In the PC programming software, make sure the “DUALCONTROL SPEAKER is programmed ACTIVE LOW .

Figure 33 - ORION Dual Control Unit Front Mount/Remote MountInstallation Configuration

INSTALLATION INSTRUCTIONS FOR REMOTEMOUNT DUAL CONTROL UNITS

1. Referring to Figure 34, run the Remote Control Cable(19B802554P3 or P4) between locations for the Radio Unit andMain Control Unit.

2. Run the Dual Control Cable (19B802554P9) between locations forthe Radio Unit and Auxiliary Control Unit. Be sure to locate theP2/P3 connector assembly at the radio unit.

40

3. After installing the Radio Unit in the normal fashion, connect thedual control cable connector (P3) to the Radio Unit. Tighten the twojackscrews on P3. Next, connect the Remote Control Cableconnector (P1) to the Dual Control Cable connector (P2), and tightenjackscrews on P2.

4. After installing the Main Control Unit in the normal fashion, connectthe Remote Control Cable (P2) to the Main Control Unit, and tightenjackscrews.

5. After installing the auxiliary control unit in the normal fashion,connect the Dual Control Cable (P1) to the Auxiliary Control Unit,and tighten jackscrews.

6. Connect the accessory cable (19B802554P6) to the AuxiliaryControl Unit. Connect either the accessory cable (19B802554P6) orthe extended option accessory cable (19B802554P7) to the MainControl Unit, as appropriate.

7. A yellow ignition sense lead is provided on each control cable. If the“Ignition Sense” feature is enabled on the Radio Unit, it isnecessary to connect only one of the yellow leads provided,whichever is convenient. Tape back the unused yellow lead. Seepage 20 for details.

8. Install the speakers in convient locations near each control unit.

9. Install a relay (19A149299P1) from the kits supplied at a locationnear the leads from each speaker. For mounting use the #8 X 3/4”sheetmetal screw and nutplate supplied with each kit.

10. At a convenient point cut one of the wires in each of the 2-wirespeaker cables, spread the leads, and strip the ends. (Crimp a 1/4” tabreceptacle to each end.

11. Main Control Unit Speaker: Connect the lead nearest the speaker toPin 87 of the relay. Connect the lead nearest the connector to Pin 30of the relay. Connect connector to the accessory cable P2 (Refer toFigure 34).

12. Auxiliary Control Unit Speaker: Connect the lead nearest thespeaker to Pin 87A of the relay. Connect the lead nearest theconnector to Pin 30 of the relay. Connect the connector to accessorycable P2 (Refer to Figure 34).

13. For Each Relay: Connect a #18 AWG black wire between the relay,Pin 85 and accessory cable P3-1 (labeled “OUT2” on schematicdiagrams in the service manual). Use a 1/4” tab receptacle on therelay side and a mating Molex connector and pins on the accessorycable side. Connect the mating Molex connector to the accessorycable P3 when finished (Refer to Figure 34).

9

INSTALLATION IN VEHICLES POWEREDBY LIQUEFIED (LP) GAS

Radio installation in vehicles powered by liquefied petroleum gaswith the LP gas container in the trunk or other sealed-off spacewithin the interior of the vehicle must conform to the National FireProtection Association Standard NFPA 58 which requires that:

• Space containing radio equipment shall be isolated by a seal from thespace containing the LP gas container and its fittings.

• Outside filling connections shall be used for the LP gas container.

• The LP gas container space shall be vented to the outside of thevehicle.

INSTALLATION

RUNNING CABLES

To assure the feasibility of the planned cable routings, it is suggested thatthe cables be run before mounting the radio. The Orion mobile radio maybe installed as a Front Mount, Remote Mount or Cassette Mount. Thetype of mount, the application and the options to be installed should beconsidered when planning the cable runs. Figures 5-12 provideInterconnection Diagrams for typical installations. Figures 5-12 shouldbe referenced throughout this manual and throughout the installation.

Be sure to leave some slack in each cable going to the radio so that theradio may be pulled out for servicing with the power applied and antennaattached. Coil any surplus cables and secure them out of the way. Try toroute the cables away from locations where they will be exposed to heat(exhaust pipes, mufflers, tailpipes, etc.), battery acid, sharp edges ormechanical damage or where they will be a nuisance to automobilemechanics, the driver or passengers. Keep wiring away from electroniccomputer modules, other electronic modules and ignition circuits to helpprevent interference to these components and radio equipment.

In addition, try to utilize existing holes in the firewall, trunk wall and thechannels above or beneath doors. Channels through door and windowcolumns that are convenient for running cables may also be used, unlessrigid or flexible conduit is to be installed for cable runs.

8

EQUIPMENT REQUIREDThe equipment required for installing the Orion Mobile Radio is listedbelow:

• Crimping Tool for fuse holder

• Electric drill for drilling mounting holes

• Drills and circle cutters as follows:

No. 31 (1/8-inch) drill

No. 27 (9/64-inch) drill

5/8-inch drill or circle cutter

3/4-inch circle cutter, hole saw or socket punch

• Phillips and flat-blade screwdrivers

• POZIDRIV driver

• No. 20 Torx driver

Torx is a registered trademark of CAMCAR Division TEXTRON, Inc.POZIDRIV is a registered trademark of Phillips International Company.

CAUTION

• Be careful to avoid damaging some vital part (fuel tank,transmission housing, etc.) of the vehicle when drilling mountingholes. Always check to see how far the mounting screws willextend below the mounting surface before installing.

• If pilot holes must be drilled, remove all metal shavings fromdrilling holes before installing screws.

41

14. For Each Relay: Connect one end of a #18 AWG red wire to therelay, Pin 86. Cut the lead to length, and connect the other end to the1 amp fuse holder supplied. Use crimp on connectors supplied.Connect the other side of the 1 amp fuse holder to the A+ batterysource or a vehicle A+ fuse block. Use a #18 AWG red wire and aring lug supplied, if needed (Refer to Figure 34).

15. Check dual control operation, using the operator’s manual as a testguide. In the PC programming software, make sure the “DUALCONTROL SPEAKER is programmed ACTIVE HIGH .

Figure 34 - ORION Dual Control Unit Remote Mount/RemoteMount Installation Configuration

42

Figure 35 - Remote Mount Dual Control Cable 19B802554P9

(19B802554, Sh.7, Rev. 19)

7

Figure 4 - Typical Installation (Remote Mount Shown)

It is suggested that the radio be installed by one of the many authorizedGeneral Electric Service Stations located throughout the United States.These experienced service stations can provide a proper radio installationand make any final adjustments that may be needed.

WARNING

• Vehicular Electronics-Electronic fuel injection systems, electronicanti-skid braking systems, electronic cruise control systems, etc.,are typical of the types of electronic devices which may be proneto malfunction due to the lack of protection from radio frequencyenergy present when a radio is transmitting. If the vehicle containssuch equipment, consult the dealer to determine if such electronicequipment will perform normally when the radio is transmitting.

• For passenger safety, mount the radio securely so that the unit willnot break loose in the event of a collision. This is especiallyimportant in station wagons, vans and similar type installationswhere a loose radio could be extremely dangerous to the vehicleoccupants.

6

Table 1 - Orion Mobile Radio Optional AccessoriesOption Description Part Number

D2AN1M 900 MHz, 1/4 Wave Whip Antenna 19B801182P3D2AN1L 800 MHz 1/4 Wave Whip Antenna 19B209568P5D2AN1R VHF/UHF, 1/4 Wave Whip Antenna 19B209568P6D2CE1V Power Cable, 7.5 M 19B802622P1D2CE1W Accessory Cable, Front Mount 19B802554P1D2CE1X Accessory Cable, Rear Mount 19B802554P6D2CE1Y Control Cable, Remote Mount, 5.5 M 19B802554P3D2CE1Z Accessory Cable, Front Mount EURO 19B802554P11D2CE5R Extended Option Accessory Cable Front Mount 19B802554P2D2CE5S EXT Option Control Cable, Remote Mount, 5.5 M 19B802554P4D2CE5T EXT Option Accessory Cable, Remote Mount 19B802554P7D2CE5U EXT Option Accessory Cable, Front Mount, EURO 19B802554P12D2CE5V Control Cable, Remote Mount, EURO, 5.5 M 19B802554P13D2CE5W EXT Option Control Cable, Remote Mount, 5.5 M 19B802554P14D2CE5Z Dual Control Cable, Remote Mount, 9.0 M 19B802554P9D2CE7A Dual Radio Cable, Remote Mount, 2.0 M 19B802554P10D2CE7B Dual Control Cable, Remote Mount, 9.0 M, EUROD2CE7C Dual Radio Cable, Remote Mount, 2.0 M, EUROD2CE9A Power Cable, 7.5 M (For 50 W or less) 19B802622P3D2LS1F Speaker, GE Label 19A149590P1D2LS1H Speaker, ERICSSON Label 19A149590P11D2MA3J Mounting Bracket Kit, Remote Control Unit 344A4584G2D2MA3N Mounting Bracket Kit, Front Mount Radio 19B802672P1D2MA3R Mounting Bracket Kit, Remote Mount Radio 19B802673P1D2MA3W Mounting Bracket Kit, Remote Mount Radio, EURO 19B802672P1D2MA3X Cassette Mounting Bracket Kit, Front Mount, EURO 19B852366P1D2MC3W Microphone, GE LabelD2MC3Z Microphone, Ericsson LabelD2MK3E Keycap Kit, SCAN Control Unit 19C852359P101D2MK3F Keycap Kit, SYSTEM Control Unit 19C852359P102D2MN1A Microphone Hanger 7141414G2

PLANNING THE INSTALLATIONFigure 4 provides an example of a typical mobile radio installation.Before starting, plan the radio installation carefully so that it will be:

• safe for the operator and passengers• convenient for the operator to use• neat• protected from water damage• easy to service• out of the way of auto mechanics• out of the way of passengers

43

DUAL RADIO UNITSThe Dual Radio feature can be configured either for two remote mountradio units or one front mount unit and one remote mount unit. In remotemount configurations the Control Unit is typically located in the vehiclecab, with the Radio Units located side-by-side in vehicle trunk. Infront/remote mount configurations the front mount unit is located in thevehicle cab, with the remote mount unit located in a convenient locationnearby. The remote/remote mount configuration is the preferredinstallation, since a separate control unit is required to program the remoteunit in a front/remote mount configuration.

The following Dual Radio Unit configurations are not allowed:

1. Any configuration using a DIN cassette mount.

2. Any installation where Extended Options are required from both RadioUnits. Extended Options are supported in one Radio Unit only.

PRE-INSTALLATION PROGRAMMINGPROCEDURE

All Radio Units in the Dual Radio configuration MUST BEPROGRAMMED prior to final installation. It is recommended that theunits be first programmed at a Service Center, then transferred to the user'sinstallation.

These configurations provide for a Master Radio Unit and a Slave RadioUnit. In the remote/remote mount configuration, the Master Radio Unit isalways the radio most directly connected to the Control Unit. In thefront/remote mount configuration, the Master Radio Unit is always the frontmount radio. Extended Options are allowed only in the Master Radio Unit.Programming each radio is straightforward, except that one radio isprogrammed as a Master, and one as a Slave.

1. Decide which Radio Unit shall be the Master Unit. Configure the radiofor programming as shown in the applicable service section manual.

2. In the "Multi-Radio" field of the PC programmer, select "Master".

3. Program unit normally. Include Extended Option features, ifpurchased.

4. Now configure the "Slave" Radio Unit for programming. Be sure touse the programming configuration for remote mount, and supply therequired control unit, if for a front/remote mount dual radioconfiguration.

44

5. In the "Multi-Radio" field of the PC programmer, select "Slave".Radio Units are now ready for vehicle installation.

6. Program normally. Do not include Extended Option features.

INSTALLATION INSTRUCTIONS FORFRONT/REMOTE MOUNT DUAL RADIOCONFIGURATION.

1. Plan the mounting locations of the two Radio Units. Note that themaximum cable length allowed between the two radios is two meters.Referring to Figure 36, run Dual Radio Cable (19B802554P10)between locations for Master and Slave Radio Units. Be sure to locatethe P2/P3 connector assembly at the Master Radio Unit.

2. After installing Master Radio Unit mounting hardware, connect theDual Radio Cable Connector (P3) to the Master Radio Unit. Tightenthe two jackscrews on P3. Next connect the Accessory Cable(19B802554P1 or P2) Connector (P1) to the Dual Radio CableConnector (P2), and tighten to jackscrews on P2.

3. Connect Microphone and Accessories. Refer to Accessory InstallationManual for proper connection of Accessories.

4. Connect Power Cable, and Antenna, then install Master Radio Unit inmounting bracket.

5. Connect "IGN A+" lead, if option is desired. Be sure internal SwitchSW601 is set properly. Refer to Page 20 of this manual for details.

6. After installing Slave Radio Unit in its mounting hardware, connectDual Radio Cable (P1), and tighten jackscrews. Be sure SW601setting on Slave Radio Unit is same as for Master Radio Unit. ConnectPower Cable and Antenna to Slave Radio.

7. Check Dual Radio operation, using Operator's Manual as test guide.

INSTALLATION INSTRUCTIONS FORREMOTE/REMOTE MOUNT DUAL RADIOCONFIGURATION.

1. Plan the mounting locations of the two Radio Units. Note that themaximum cable length allowed between the two radios is two meters.Referring to Figure 37, run Dual Radio Cable (19B802554P10)between locations for Master and Slave Radio Units. Be sure to locatethe P2/P3 connector assembly at the Master Radio Unit.

5

Figure 3 - Cables

4

• Front Mount Bracket Kit D2MA3N

or

• Remote Mount Kit D2MA3R

with

• Control Unit Mount Kit D2MA3J

• Operator's Manual LBI-38888

• Installation Manual LBI-38901

Figure 1 - Orion Mobile Radio Components And Mounting Hardware

Figure 2 - Rear View Of Radios

USA EURO

45

2. After installing Master Radio Unit mounting hardware, connect theDual Radio Cable Connector (P3) to the Master Radio Unit. Tightenthe two jackscrews on P3.

3. Next route the Remote Control Cable (19B802554P3 or P4) betweenControl Head and Master Radio locations. After installing ControlHead, connect Remote Control Cable Connector (P2) to Control Head.

4. Connect "IGN A+" lead, if option is desired. Be sure internal SwitchSW601 on Master Radio is set properly. Refer to Page 20 of thismanual for details.

5. Connect Accessory Cable (19B802554P6 or P7) Connector (P1) toControl Head.

6. Connect Microphone and Accessories. Refer to Accessory InstallationManual for proper connection of Accessories.

7. Now connect Remote Control Cable Connector (P1) to the Dual RadioCable Connector (P2), and tighten to jackscrews on P2.

8. Connect Power Cable, and Antenna, then install Master Radio Unit inmounting bracket.

9. After installing Slave Radio Unit in its mounting hardware, connectDual Radio Cable (P1), and tighten jackscrews. Be sure SW601setting on Slave Radio Unit is same as for Master Radio Unit. ConnectPower Cable and Antenna to Slave Radio.

10. Check Dual Radio operation, using operator's manual as test guide.

46

Figure 36 - Orion Dual Radio Front Mount InstallationConfiguration

Figure 37 - Orion Dual Radio Remote Mount InstallationConfiguration

3

INTRODUCTIONThis manual contains installation instructions for the Orion Mobile RadioUnit and associated accessories. These instructions cover the mountingand cabling of the radio; interconnection and wiring diagrams areprovided for reference. Before installation the radio should beprogrammed using an IBM compatible personal computer and thefollowing items:

Serial/Flash Programming Interface Module TQ3370

Programming Cable TQ3377

EDACS Programming Software TQ3374

or

Conventional Programming Software TQ3367

IMPORTANT NOTICE

ORION UHF MOBILES

The PC programmer automatically defaults the receiver oscillator shift toposition No. 2. When field programming the receive frequencies forORION UHF mobiles, the oscillator shift must be programmed toposition No. 1 or No. 3. Enter the CONVENTIONAL and/or TRUNKEDFREQUENCY SET screen of the PC programmer and set the values inthe “OS” column to “1” or “3”.

UNPACKING AND CHECKING EQUIPMENTCarefully unpack the radio and identify each item in the shippingcontainer as listed below. If damage has occurred to the equipmentduring shipment, file a claim with the carrier immediately. The availableoptions for the Orion Mobile Radio are covered in Table 1.

• Orion Mobile Radio Unit

• Microphone D2MC3W or D2MC3Z

• Speaker D2LS1F or D2LS1H

• Power Cable D2CE1V or D2CF9A

• Control Cable D2CE1Y

2

TABLE OF CONTENTS

INTRODUCTION................................................................................3UNPACKING AND CHECKING EQUIPMENT................................3PLANNING THE INSTALLATION ...................................................6EQUIPMENT REQUIRED..................................................................8INSTALLATION IN VEHICLES POWERED BY LIQUEFIED(LP) GAS..............................................................................................9INSTALLATION .................................................................................9

RUNNING CABLES...................................................................9Power Cable........................................................................12Accessory Cable .................................................................13Ignition Sense .....................................................................20Control Cable (Remote Mount Only) .................................21

CONTROL UNIT MOUNTING (REMOTE APPLICATIONSONLY)................................................................................21

SPEAKER D2LS1F...................................................................26MICROPHONE HANGER AND/OR HOOKSWITCHMOUNTING .............................................................................26RADIO MOUNTING AND FINAL HOOK-UP.......................27

Front Mount........................................................................27Remote Mount Installation .................................................29Cassette Mounting (EURO Only) .......................................30Cassette Assembly Mounting..............................................31

DUAL CONTROL UNITS.................................................................34PREINSTALLATION PROGRAMMING PROCEDURE

-- FRONT MOUNT............................................................34PREINSTALLATION PROGRAMMING PROCEDURE

-- REMOTE MOUNT ........................................................36INSTALLATION PROGRAMMING FOR FRONT MOUNT

DUAL CONTROL UNITS.................................................38INSTALLATION INSTRUCTIONS FOR REMOTE MOUNT

DUAL CONTROL UNITS.................................................39DUAL RADIO UNITS.........................................................................43

This manual is published by Ericsson Inc., without any warranty. Improvements andchanges to this manual necessitated by typographical errors, inaccuracies of currentinformation, or improvements to programs and/or equipment, may be made by EricssonInc., at any time and without notice. Such changes will be incorporated into new editionsof this manual. No part of this manual may be reproduced or transmitted in any form or byany means, electronic or mechanical, including photocopying and recording, for anypurpose, without the express written permission of Ericsson Inc.

Copyright© October 1993 Ericsson GE Mobile Communications Inc.

47

Figure 38 Dual Radio Control Cable (19B802554P10)

(19B802554, Sh.8, Rev. 19)

Ericsson Inc.Private Radio SystemsMountain View RoadLynchburg, Virginia 245021-800-528-7711 (Outside USA, 804-528-7711) Printed in U.S.A.

ericssonz

LBI-38901F

Installation Manual

Orion™ Mobile Radio